Machine for cutting pouches with shaped perimeter edge, and method

ABSTRACT

Apparatus and method for separating product containing pouches from a travelling web of adhered films carried on a film support surface includes a rotary blade drum assembly having blade configurations with blade portions arranged to form the entire perimeter edge of the flange of the pouch which rotate in synchronous registration with grooves in the film support surface. In one form, at least one blade portion and associated groove portion are non-linear and other than longitudinal or transverse to the film support surface of the forming drum or travelling web of films. The blade portions may be heated and the rotary blade drum assembly may include insulating guides for the pouches.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority pursuant to 35 USC § 120 to U.S.non-provisional application Ser. No. 15/812,601, filed Nov. 14, 2017,entitled “Machine for Cutting Pouches with Shaped Perimeter Edge, Methodand Pouch,” which, in turn, claims priority pursuant to Title 35 USC §19(e) to U.S. provisional application Ser. No. 62/422,346, filed Nov.15, 2016, for “Machine for Cutting Pouches with Shaped Perimeter Edge,Method and Pouch,” the entire specification and drawings of which arehereby incorporated by reference herein as if fully set forth.

BACKGROUND

This disclosure relates to flexible, composition containing pouchesformed of polymeric film and the apparatus and method of making them.More particularly, it is related to a mechanism for separating completedpouches from a travelling web of adhered film material, the method ofdoing so and the resultant pouches.

Flexible pouches made of polymeric film and filled with a consumableproduct are commonly produced on equipment having an array of pouchforming mold configurations. These pouch forming mold configurations areoften incorporated into a rotating drum, or axially movable platen.Examples of such forming, filling and sealing systems include U.S. Pat.No. 3,218,776, issued Nov. 23, 1965 to Charles E. Cloud, and U.S. Pat.No. 9,162,413, issued to Cloud Packaging Solutions, LLC, the entirecontents of which are hereby incorporated herein by reference as iffully set forth.

Machines or systems are known for forming flexible sealed pouches orpackages containing a consumable product. Such pouches may be made fromtwo continuous films in which a first or base film is vacuum formed intomold configurations on a rotating forming drum to define pockets to befilled with one or more products or materials and subsequently closed bya second or lid film. Some more recent configurations include multiplecompartment pouches, and pouches in which more than two films areemployed.

A known two-layer pouch may be made of PVA or similar soft, deformablepolymeric material. It includes a central product containing chamberhaving a perimeter seal defined by the edge of the mold configuration ofa forming drum. Typically, the process for separation of the completedpouches from the web of adhered films results in creation of a perimeterflange that has a rectangular or square perimeter edge configuration. Onrelease of a completed pouch from its mold cavity, the known shrinkageof the base film and complementary stretch or expansion of the lid filmcause the resultant shape of a completed pouch.

Traditionally, the formed and filled pouches are cut from the continuousweb of adhered films using stationary slitting blades that cut themoving web into longitudinal strips. Thereafter, rotating transverseblades cut the strips between rows of pouches to separate the stripsinto individual pouches. The result is a filled pouch with a perimeterflange of surrounding material comprising adhered layers of film havinga rectangular or square perimeter edge.

A modern example of such a machine and process for forming such pouchesis disclosed in previously identified U.S. Pat. No. 9,162,413.

The foregoing process is particularly suitable for producing flexiblepackages from water soluble film, such as polyvinyl alcohol (PVA). Ahighly successful application involves manufacture of individual dosagepouches of liquid laundry detergent and/or liquid dish washingdetergent, though other commercial applications are also known.

The industry has, for some time, contemplated production of formedfilled and sealed pouches with a more cost effective, or attractiveshape, particularly, a pouch with a unique rectangular surroundingperimeter flange. This disclosure provides mechanism and method forseparating pouches that attain those goals. In particular, it providesthe capability to produce pouch shapes having non-rectangular perimeteredges resulting in unique and attractive pouch shapes that wereheretofore unobtainable.

SUMMARY

Apparatus and method for separating product containing pouches from atravelling web of adhered films carried on a film support surfaceincludes a rotary blade drum assembly having blade configurations withblade portions arranged to form the entire perimeter edge of the flangeof the pouch which rotate in synchronous registration with grooves inthe film support surface. In one form, at least one blade portion andassociated groove portion are non-linear and other than longitudinal ortransverse to the film support surface of the forming drum or travellingweb of films. The blade portions may be heated and the rotary blade drumassembly may include insulating guides for the pouches.

Apparatus for separating product containing pouches from a travellingweb of adhered films includes a film support surface carrying adheredfilms and provided with at least one pouch forming mold configurationand surrounding groove portions. A rotary blade drum assembly with bladeportions to form the entire perimeter edge of a flange of the pouch isdisposed for synchronous registration with the groove portions. Rotationof the rotary blade drum causes the blade portions to enter the grooveportions through the travelling web of adhered films and form theperimeter edge of the flange of the pouch and separate the pouch fromthe travelling web of adhered films.

The film support surface includes intersecting generally longitudinalgroove portions and generally transverse groove portions, and the rotaryblade drum assembly includes intersecting generally longitudinal bladeportions and generally transverse blade portions configured forsynchronous registration. In one form, at least one of the generallylongitudinal blade portions or generally transverse blade portions isnon-linear relative to the longitudinal or transverse extent of theforming drum or travelling web of adhered films. The rotary blade drumassembly may include heating elements to heat the blade portions to atemperature sufficient to melt the adhered web of films and insulatingpads or guides disposed within each blade configuration arranged todefine a generally cylindrical forming drum contact surface to contactpouches being separated from the travelling web of adhered films.

A method of separating product containing pouches from a travelling webof adhered films defining a plurality of pouches carried by the webincludes providing a film support surface for carrying the web andhaving a plurality of transverse rows of mold configurations definingmold cavities, each supporting a pouch therein, with a plurality ofgenerally longitudinal and generally transverse groove portionssurrounding each mold configuration; providing a rotary blade drumassembly in operative relation with the film support surface havingblade configurations with blade portions arranged to form the entireperimeter edge of the flange of each pouch disposed for synchronousregistration with the groove portions of the film support surface tocause the blade portions to enter the groove portions through thetravelling web of adhered films to form a perimeter edge of each flangeof each pouch, and causing synchronous registrations of the bladeportions and groove portions to separate the pouches from the travellingweb of adhered films.

A forming drum for separating product containing pouches from atravelling web of adhered films comprises a film support surface forcarrying the web of adhered films with a plurality of pouch forming moldconfigurations with groove portions surrounding each mold configurationincluding intersecting generally longitudinal groove portions andgenerally transverse groove portions arranged for synchronousregistration with blade portions on an associated rotary blade drumassembly with at least one of the groove portions of each moldconfiguration being non-linear relative to the longitudinal ortransverse extent of the forming drum.

A rotary blade drum assembly for separating product containing pouchesfrom a travelling web of adhered films carried on a film support surfacewith a plurality of pouch forming mold configurations each surrounded bygroove portions includes blade configurations with blade portionsarranged to form the perimeter edge of a flange of a pouch and arrangedfor synchronous registration with the groove portions in the formingdrum, rotation of forming drum and rotary blade drum causing the bladeportions to enter the groove portions through the travelling web ofadhered films and form the perimeter edge of the flange of the pouch andseparate pouches from the travelling web of adhered films.

A product containing pouch of adhered films defines at least oneinterior volume with a perimeter flange having a perimeter edge definedby intersecting generally longitudinal and generally transverse edgeportions, where at least one of the edge portions is non-linear.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a flexible product containment pouchconfiguration.

FIG. 2 is a cross-sectional view of the pouch of FIG. 1 taken along theline 2-2 of FIG. 1 .

FIG. 3 is a schematic view of an exemplary rotary form, fill and sealmachine for making pouches in accordance herewith.

FIG. 4 is a top view of a flexible product containment pouch produced inaccordance with the principles of this disclosure.

FIG. 5 is a cross-sectional view of the pouch of FIG. 4 taken along theline 5-5 of FIG. 4 .

FIG. 6 is a partial perspective view of a portion of a long bar of abase forming drum showing a mold configuration in accordance with thepresent disclosure.

FIG. 7 is a perspective view of a plurality of long bars as shown inFIG. 6 , assembled to form a base forming drum, such as the base formingdrum of FIG. 3 .

FIG. 8 is a perspective view of a rotary blade drum assembly configuredin accordance with the disclosure.

FIG. 9 is a partial plan view of the base forming drum and rotary bladedrum assembly shown in FIGS. 7 and 8 illustrating details of theinteraction between them.

FIG. 10 is a perspective view similar to FIG. 9 on an enlarged scale.

FIG. 11 is a perspective view of a rotary drum and rotary blade drumcomponent of a rotary form fill and seal packaging machine illustratingthe principles of the present disclosure in an alternative form.

FIG. 12 is a perspective view of a flexible product containment pouchmade in accordance with the principles of the present disclosure.

FIG. 13 is a partial view in perspective of a pouch separation apparatusin accordance with the disclosure for making pouches illustrated in FIG.12 .

FIG. 14 is a perspective view of a portion of the apparatus of FIG. 13illustrating various features of the disclosure.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

In this disclosure, longitudinal or circumferential means in thedirection of movement of the travelling web of adhered films orperpendicular to the axis of rotation of the base forming drum.Transverse or lateral means across the film, or parallel to the axis ofrotation of the drum. Also, in reference to the web of combined films,“longitudinally” means along the length of the web of films.“Transversely” means across the films of the web from edge-to-edge. Theterm “non-linear” means not parallel to the longitudinal or transverseextent of the forming drum or travelling web of adhered films.

Turning now to the drawings, FIGS. 1 and 2 are illustrative of aflexible containment pouch 100 formed by joinder of two polymeric films.The films could be water soluble polyvinyl alcohol, though other filmscould be used. The films used are “soft” and form “soft” blisters oncethermoformed from PVA, polyethylene, or other suitable polymeric film.

Typical film thicknesses for soft blister pouches are 0.001″ (inch) to0.004″ (inch) thick. The formed stock, sometimes called the base film istypically around 0.003″ (inch) thick and the lid stock or lid film istypically thinner, usually around 0.002″ (inch) thick, though thesethicknesses not requisite for the principles of this disclosure.

Referring to FIGS. 1 and 2 , pouch 100 includes a base film 102 and alid film 104 joined along a sealed interface 106 of adhered films. Itdefines a hollow interior volume containing a product component 110, inthis illustration, a liquid composition.

The pouch 100 has a generally rectangular perimeter flange 111 withparallel longitudinal edge portions 112 and parallel transverse edgeportions 114.

The pouch 100 of FIGS. 1 and 2 is illustrative of a resultant productthat may be produced in accordance with the principles of thisdisclosure. It is, however, only illustrative and, as explained indetail below, the principles disclosed herein have a wide range ofapplicability and benefit, including production of shaped pouches notpreviously attainable.

FIG. 3 is a representation of a rotary pouch forming and fillingapparatus suitable for producing a plurality of the pouches 100 depictedin FIGS. 1 and 2 , in accordance with the principles of the presentdisclosure, as well as the unique pouches depicted in FIGS. 4 and 5, 11or 12 , all as discussed further below. The pouch forming apparatus isgenerally similar to that disclosed in aforementioned U.S. Pat. No.9,162,413. Of course, the principles disclosed are fully applicable toother pouch forming apparatus, including, but not limited to, movableplaten machines.

A rotatable base forming drum 120 includes multiple transverse rows ofpouch forming mold configurations defining mold cavities to producemultiple pouches simultaneously. Typically, the rotary drum 120 isformed of a plurality of long bars 121 supported on a wheel and definingan outer film support surface 123. Each bar 121 includes multiple moldconfigurations or cavities extending inward of the drum from filmsupport surface 123. As described in detail with respect to theembodiment of the disclosure discussed with reference to FIGS. 4 through10 , film support surface 123 of base forming drum 120 includesgenerally circumferential or longitudinal and generally transversegrooves surrounding each mold configuration that parallel the shape ofthe edge defining the cavity of each mold configuration.

The pouch forming apparatus additionally includes a vacuum system 130, aheater system 140, a product feed mechanism 145, a wetting system 160, asealing system 170, a pouch separation station 180, and rolls ofmaterial that supply base film 102, and lid film 104.

Vacuum system indicated generally at 130 in FIG. 3 , includes conduits132, operatively connected to each mold configuration to create a vacuumto draw a portion of the base film 102 into the mold cavities to formproduct receiving pockets in base film 102. Such a vacuum system is wellknown in the art. A drive system (not shown) is operatively connected tothe base forming drum 120 to rotate the drum continuously about its axisin direction “A.”

The heater system 140 is depicted as a rotatable base film heater roller142 positioned adjacent the base forming drum 120. It includes aninternal element to heat the base film 102 prior to it contacting thefilm support surface 123 of base forming drum 119 or being drawn intomold configurations to form product pockets. The heater system 140 maybe configured as a cartridge-type heater within the base film heaterroller 142 but other types of heaters, either internal or external to aroller, may be used if desired. In a typical method of thermoforming,for example, PVA or similar film, on a rotary drum form fill and sealpouch machine, the film is heated to a range of 140° F. to 400° F.depending on film thickness, type of film and other operationalparameters.

A product feed mechanism 145 is positioned generally adjacent the baseforming drum 120 to supply one or more product components into eachproduct pocket as the pockets, together with base film 102, move alongwith the film support surface 123. Product feed mechanisms 145 are wellknown in the art and may take any known form. Such mechanisms may beconfigured to feed any desired type of composition, number orcombination of individual products and/or materials, preferablyincluding a liquid composition. Of course the product could comprise agel, a solid, a powder, a paste or wax-type products, pills, tablets, oreven other pouched products.

A supply roll of continuous film material provides the lid film 104. Thelid film 104 is aligned with the base film 102 so as to come intooverlying contact with the base film 102 after the filling of thepockets in the base film. The illustrated lid wetting system 160 helpscreate a strong seal between the base film and lid film. It ispositioned adjacent the lid film 104 at a position upstream of where thelid film 104 seals the base film 102 at the base forming drum 120.

The lid wetting system 160 may apply a solvent to the lid film 104 toincrease its tackiness to assist in adhering the lid film 104 to thebase film 102. To do so, the solvent may be provided through a wettingreservoir 162 to a wetting roller 163 that engages the lid film 104. Ininstances where the base film 102 and lid film 104 are formed of apolyvinyl alcohol material, the solvent for the lid wetting system 160may be water.

A sealing system 170 having a sealing roller 172 is positioned in closecontacting relation to the film support surface 123 of base forming drum120. Lid film 104 passes around sealing roller 172 and is urged intosealing contact with base film 102 to urge the contacting surfaces ofbase film 102 and lid film 104 into adhering, sealed relation. In thisregard, the sealing roller 172 is mounted such that it applies pressureto the overlying films to perfect the sealing relationship. Sealingroller 172 may include an outer layer 173 formed of material that isdeformable, such as a rubber or similar material, though this is notessential. Typically, this material has a thickness of about one-halfinch (½″) and a durometer of about 60, though these values may vary. Thematerial, and the pressure exerted on the overlying films, assureseffective contact of base film 102 and lid film 104 along the sealedinterface 106. Of course, depending on the film material, it is alsoknown to use heat, ultrasonic welding or other similar process to sealthe lid film and base film together to form a completed pouch.

Pouches formed of polymeric material, such as polyvinyl alcohol, areprone to shrinkage and distortion after forming, filling and sealing.When located in the cavity, the applied vacuum through conduits 132retains the shape dictated by the mold configuration. Once released,however, the pouch base pocket shrinks to a smaller volume, sometimes upto twenty or more percent (20%) smaller. Because the pouch 100 issealed, the shrinkage is accommodated with stretching of lid film 104 toform the shape shown in FIG. 2 . Often lid film 104 is a thinnermaterial than base film 102 to augment the expansion characteristic ofthe lid film.

The foregoing mechanism comprises a typical rotary form fill and sealpouch forming machine with a base forming drum carrying a travelling webof adhered films interspersed with filled product component chambers.The description to follow describes apparatus and method in accordancewith this disclosure for removal of the product component pouches fromthe travelling web. This apparatus and method provide the capability toproduce individual pouches of unique configurations.

A pouch separation system 180 is positioned after, or downstream fromthe location at which the base film 102 and the lid film 104 are securedtogether to form the web of adhered films. It comprises a rotary bladedrum assembly 150 configured in accordance herewith to coact with thebase forming drum 120 to individually separate each completed pouch fromthe travelling web of adhered films.

The cooperative machine elements and their functional coaction areillustrated and described in detail below in relation to production of aunique pouch configuration illustrated in FIG. 4 . The surroundingflange of this pouch has non-linear perimeter edge portions. Asillustrated in additional embodiments below, the disclosed apparatus andmethod possess the capability to produce any number of variations ofpouches with flanges having non-linear perimeter edge portions in eitherthe longitudinal or the transverse direction of the web of adheredfilms. It is also to be understood that the systems and principlesdisclosed herein are employed in the pouch separation station 180 ofFIG. 3 for production of pouches as illustrated in FIGS. 1 and 2 ,having a rectangular perimeter flange and linear longitudinal andtransverse edge portions.

A preferred apparatus and method for creating shaped pouches inaccordance with this disclosure is disclosed in reference to FIGS. 4 to10 . In this embodiment, a pouch separation station 280 is illustratedand described.

Referring to FIGS. 4 and 5 , illustrative pouch 200 includes a base film202 and a lid film 204 joined along a sealed interface 206 to form a webof adhered films. Two separate interior volumes are separated by web 207of adhered films 202 and 204. Each separate volume contains a productcomponent 210, which may be the same or a different composition, usuallya liquid, or other suitable material.

Pouch 200 includes a surrounding flange 211 formed by the adhered films.In this illustration, flange 211 has non-linear longitudinal edgeportions 212 and parallel, linear edge portions 214 (designated 214L or214T in FIG. 4 ) that together define the perimeter edge 215 of thepouch 200. Here, longitudinal edge portions of perimeter edge 215present a wavy or zig-zag shape. Though illustrated as a combination ofstraight lines, the edge portions 212 or 214 could be any shape,including curved or arcuate. Moreover, either of the edge portions couldbe oblique to the longitudinal or transverse extent of the forming drumor travelling web of adhered films from which the pouch is separatedand, in that sense, non-linear.

As in the earlier machine, described in connection with FIG. 3 , baseforming drum 220, a portion of which is seen in FIG. 7 , includescylindrical outer film support surface 223 formed by the exteriorsurface of assembled long bars 221. As illustrated in FIG. 7 , each longbar 221 includes a plurality of rows of mold configurations 224. Inoperation, the base film 202 for a pouch is supported upon the outerfilm support surface 223 during the pouch forming and filling steps ofthe pouch making process. After filling, lid film 204 is adhered to thebase film 202 in the well-known manner. Rotating base forming drum 220carries the travelling web of adhered films through the pouch productionprocess. The combined web of adhered films of two or more layers thenadvance to the pouch separation system 280, seen in FIGS. 9 and 10 ,with the completed pouches retained by vacuum within the cavities ofmold configurations 224.

Referring to FIG. 6 , there is shown an illustration of a moldconfiguration 224 for pouch forming drum 220 that produces a pouchhaving a modified flange configuration with a unique perimeter edgeillustrated in FIGS. 4 and 5 . Rather than the typical rectangularflange shape produced with known web slitting and cutting mechanisms,the resultant pouch here has a perimeter flange 211 with a perimeteredge 215 that follows the profile of the mold configuration 224. Theillustrative pouch produced by the machine of this disclosure is amulti-compartment pouch with two chambers; however, the principles ofthis disclosure are equally applicable to single compartment pouches, orpouches with more than two chambers.

FIG. 6 illustrates a portion of one of the long bars 221 illustrated inFIG. 7 . A plurality of such long bars 221 are assembled to form a baseforming drum 220 as seen in FIG. 7 . Grooves 226 and 228 intersect tosurround each mold configuration 224 of the base forming drum 220.

With reference to the mold configuration 224 of FIG. 6 , two cavitysegments 224 a and 224 b are present, divided by a central divider 223 cco-extensive with the outer film support surface 223. These cavitiesrepresent two separate chambers of the multi-chamber pouch shown inFIGS. 4 and 5 . Notably, these chambers are defined by an irregularpattern perimeter edge 230 of the mold configuration 224.

As best illustrated in FIG. 6 , the long bars 221, and consequently theexterior surface of the drum 220, the outer film support surface 223, isprovided with radially inwardly directed generally longitudinal orcircumferential grooves 226 between each pouch mold configuration 224(in a given row) and radially inwardly directed generally transversegrooves 228 between each row of mold configurations 224. With the longbars 221 so assembled, the outer film support surface 223 presents auniform pattern of circumferentially spaced cavities of moldconfigurations 224 in transversely spaced rows, each surrounded bygrooves defining a continuous pattern of intersecting generallycircumferential grooves 226 and generally transverse grooves 228. Asdisclosed herein, such grooves may be non-linear. Thus, in thisillustrated embodiment, the grooves represent a departure from priorarrangements, which have previously comprised only linear groovesextending longitudinally and transversely of a base forming drum, suchas base forming drum 120 of FIG. 3 . Moreover, the grooves of thisillustrated embodiment coact with pouch separation system 280 in a newand heretofore unknown manner essential to the disclosed process forremoval of individual completed pouches from the continuous web ofcombined base and lid films.

Referring again to FIG. 6 in this illustration, the transverse grooves228 are straight, or linear, and arranged parallel to the axis ofrotation of the base forming drum 220. However, the longitudinal orcircumferential grooves 226 are arranged in a non-linear manner anddefine a wavy or zig-zag pattern that closely parallels the shape ofperimeter edges 230 of the mold configuration cavities. Notably, asillustrated in FIG. 6 , the separate mold configurations 220, formingseparate pouches, may be nested in the transverse direction along thesurface of each long bar 221, reducing the overall width of the baseforming drum 220, or alternatively permit inclusion of an additionalmold configuration in each row to increase capacity.

The capability for creating pouches in accordance herewith derives fromimplementation of the separation system 280, including illustratedrotary blade drum assembly 250 described below, which separates theentire pouch from the moving web of films carried on base forming drum220.

Referring to FIGS. 8 and 9 , illustrated a rotary blade drum assembly250 is configured to operatively coact with the travelling web of filmon base forming drum 220 in register with generally circumferential andgenerally transverse grooves 226 and 228 to extract individual completedpouches from the film. As illustrated in the drawings, particularly FIG.3 and FIGS. 8 through 10 , the rotary blade drum assembly 250 is mountedin the rotary form, fill and seal machine with its rotational axisaligned with the rotational axis of the base forming drum 220.

Rotary blade drum assembly 250 is positioned downstream of the forming,filling and sealing stations and is thus arranged to engage thetravelling web of adhered base and lid films 202 and 204 after formationof filled and sealed pouches 200 integral to the adhered films. As isnormal in such a machine, it is contemplated that the base film remainsunder vacuum within the mold configuration cavities 224 (here 224 a and224 b) until an individual pouch 200 is separated from the film. Thesepouches may then be deposited on a conveyor, such as conveyor 190, shownin FIG. 3 , on release of the applied vacuum.

Rotary blade drum assembly 250 is powered by the form, fill and sealmachine to rotate in synchronization with the base forming drum 220 andin registry with mold configuration cavities 224, and consequently, theadvancing films supported on film support surface 223 of drum 220.Rotary blade drum assembly 250 may be carried by a pneumatic cylinderdriven, slidable carriage, for translation toward and away from baseforming drum 220 to operatively associate these elements prior toinitiation of the pouch separation process. Of course, any othersuitable mechanism may be employed to move the rotary blade drumassembly 250 relative to the forming drum 220.

The rotatable forming drum 220 and rotary blade drum assembly 250 may bepowered, for example, by synchronous servo-motors with computerizedcontrol circuitry to ensure proper operational positioning andinteraction. Rotary blade drum assembly 250 may be powered, aspreviously described, for controlled rotational movement about an axisparallel to the axis of rotation of base forming drum 220 in direction“B” shown in FIG. 8 .

As seen in FIG. 8 , rotary blade drum assembly 250 has a generallycylindrical roller portion 254 with an elongate bearing shaft 252extending from its ends. Shaft 252 may be mounted upon previouslydescribed axially translatable carriage for controlled positioning inrelation to base forming drum 220.

Assembly 250 includes a roller portion 254 having an outer cylindricaldrum contact surface 255 defined by resilient insulating pads or guides270 described more fully below. The roller portion 254 has an axiallength generally coextensive with the transverse width of base formingdrum 220. When the base forming drum 220 and rotary blade drum assembly250 are in operative relation to each other, outer cylindrical drumcontact surface 255 is in rolling contact with lid film 204 of thetravelling web of adhered films 202 and 204. Of course, film 202 iscarried upon film support surface 223 of base forming drum 220.

The rotary blade drum assembly 250 is urged toward rotating base formingdrum 220 to maintain this operating relationship. The effective diameterof the outer cylindrical drum contact surface 255, defined by the outersurfaces of insulating pads 270, is such that the outer film supportsurface 223 and the cylindrical drum contact surface 255 of rotary bladedrum assembly 250 travel at the same linear velocity.

As seen in FIGS. 8 and 9 , rotary blade drum assembly 250 includesgenerally longitudinal or circumferential blade portions 266 andgenerally transverse blade portions 268 that extend radially outward ofouter cylindrical drum contact surface 255. The blade portions 266 and268 may be machined or otherwise formed or affixed to rotary blade drumassembly 250. They are formed to interengage with the grooves 226 and228 machined into the base forming drum 220, both parallel to the axisof the forming drum 220 and circumferentially in the direction ofrotation of the forming drum.

In this illustrated embodiment, the blades 266 and 268 include distalends that extend radially outward of outer cylindrical drum contactsurface. Blades 266 and 268 are configured to mesh with the generallycircumferential grooves 226 and generally transverse grooves 228 of thebase forming drum 220. The grooves 226 and 228 intersect to surroundeach mold configuration. Consequently, the blade portions 266 and 268also intersect to define the perimeter edge 215 of pouch 200. Thus, theblade portions 266 and 268 form a separation pattern sized and arrangedto engage the web of films and separate a single pouch 200 within eachperimeter. The distal edges of the blades extend somewhat beyond theinsulating pads 270. This allows the blades to enter the groovesmachined into the drum 220 without touching the drum. At maximumpenetration, the distal end portions of the blade portions 266 and 268should enter the grooves 226 and 228 usually about ⅜″ (inch) and usuallynot less than 1/16″ (inch). Note that this dimension is important toextraction of each pouch from the travelling web of adhered films 202and 204. The greater the penetration, the higher the separation forceapplied to the web of films by the blades 266 and 268 at the tangentline of contact between outer film support surface 223 and generallycylindrical forming drum contact surface 255 of rotary blade drum 250.

The blade portions 268 are arranged in a transverse linear pattern alongthe transverse length of the rotary blade drum 250. Hence, all pouchesin a single long bar 221 are separated from the film simultaneously. Inthe circumferential direction, the pattern of blade portions 266advances sequentially as the drums 220 and 250 rotate and follows thezig-zag or wavy pattern laterally in accordance with the desiredperimeter shape of the perimeter flange of the pouch to be formed.

As illustrated, the rotary blade drum assembly 250 has four completepatterns of intersecting blade portions 266 and 268 circumferentially ofdrum 250. The illustrated base forming drum 220 is comprised of fortylong bars 221 forming the cylindrical drum outer film support surface223. Rotary blade drum assembly 250 has a diameter substantially smallerthan the diameter of base forming drum 220 with blades 266 and 268 inregister with grooves 226 and 228. As explained, the outer film supportsurface 223 and outer cylindrical drum contact surface 255 travel at thesame linear velocity to maintain synchronous registry between the blades266 and 268 and grooves 226 and 228.

It should be noted that in order to efficiently separate the web ofadhered films and pouches, the rotary blade drum assembly 250 includesaxial bores into which are inserted wound cartridge resistive heatingelements 251, seen in FIG. 10 . These heaters heat blade portions 266and 268 to a temperature sufficient to melt and puncture the web ofadhered films on contact, usually between 300° and 400° F. Of course,any suitable known heating arrangements may be utilized to heat theblades of blade drum assembly 250.

To prevent the heated rotary blade drum 250 from damaging the pouchesduring the separation process, each intermediate area within theperimeter defined by intersecting circumferential and transverse bladeportions 266 and 268, is provided with insulating material in the formof the pads or blocks 270. These pads protect the pouches within thearea defined by the intersecting blades from undesired contact withmetal elements of rotary blade drum assembly 250. FIGS. 8 and 9 bestillustrate the pads 270 positioned within the space defined by bladeportions 266 and 268. Importantly, the insulating pads 270 contact eachformed pouch and urge the pouches toward the associated moldconfiguration in the base forming drum 220 during the separation processto prevent the tensioned film from prematurely recovering and changingthe shape of the pouch or causing pouch movement, which could adverselyaffect pouch separation effectiveness or result in damage to theseparated pouches. The function of pads 270 and exemplary structuralintegration to the rotary blade drum assembly 250 is fully disclosed inpreviously mentioned U.S. Pat. No. 9,162,413.

As illustrated here, generally circumferential blade portions 266 andgenerally transverse blade portions 268 may be machined upon a solidcylindrical metal roller portion 254. Separate insulating pads or blocks270 may be secured within the cavity surrounded by each intersecting setof blade portions 266 and 268 by fasteners 271, best seen in FIG. 10 .Such insulating pads may be made of silicone and have a durometer of 40to 80. They may have a radial thickness of ½″ (inch) or more. The padsmay be made of any suitable material to perform the disclosed functions.

FIGS. 9 and 10 best illustrate the interrelation between the grooves 226and 228 of base forming drum 220 and the blade portions 266 and 268 ofrotary blade drum 250. Importantly, these rotary elements are disposedon opposite sides of the travelling web of films 202 and 204 with theirrespective axes of rotation spaced such to ensure that the distal endsof blade portions 266 and 268 are in registry to fully enter grooves 226and 228, but without contact with the drum 220. This relationship, inturn, ensures a clean (sharply defined) perimeter edge of the separatedpouches.

FIG. 9 , in particular, illustrates the wavy or zig-zag pattern of thegenerally circumferential grooves 226 of drum 220 and blade portions 266of rotary blade drum assembly 250. It also shows how the grooves 226 and228 and blade portions 266 and 268 completely surround each moldconfiguration cavity 224 of base forming drum 220.

For illustrative and descriptive purposes, in reference to FIG. 4 ,based on the direction of rotation of the forming drum 220 and directionof travel of the web of adhered films, the transverse edge portion 214Lof pouch 200 is the leading edge and the transverse edge portion 214T isthe trailing edge. During separation of a pouch from the travelling webof films 202 and 204 by the pouch separation system 280, the leadingedge portion 214L is formed or separated first, followed by progressiveseparation along the longitudinal edge portions 212. Finally, system 280forms transverse edge portion 214T to completely separate a pouch 200from the adhered films. As the drum 220 and accompanying film advances,blade portions 266 and 268 of rotary blade drum assembly 251 separateeach pouch along irregularly shaped perimeter edges of the surroundingflange of adhered base and lid films. As can be seen in theillustrations of FIGS. 8 and 9 , the transverse blade portions 268parallel to the axis of rotation of the rotary blade drum assembly 250are disposed in a straight or linear fashion, as are the generallytransverse grooves 228. The longitudinal blade portions 266 in thecircumferential direction of the drum 220 are formed in a wavy linecorresponding to the pattern for the grooves 226 machined into the drum220, (which follow the pattern of the perimeter edge portions 212 of themold cavities 224).

It should be understood that the separation process disclosed does notinvolve a “cutting” such as a physical crush or shearing of the web offilms. Rather, it is a “melt” process in that the distal edges of bladeportions 266 and 268 operate at a temperature above the melting point ofthe films. The distal edges penetrate the adhered web of films andenter, but do not contact, surfaces grooves 226 and 228 of the baseforming drum 220. These edges separate each of the pouch configurationsfrom the travelling web without contact with the base forming drum 220.

The uncut sheets of PVA or other film formed with integral completedpouches is carried on the surface 223 of the forming drum 220. Thepouches are held within the cavities of the mold configuration 224 andthe combined base and lid films 202 and 204 are stretched taut againstthe smooth outer surface of drum 220. When the heated blade portions 266and 268 of rotary blade drum assembly 250 enter the grooves 226 and 228,they melt through the film creating clean separation completelysurrounding the pouch to form pouch perimeter edge 215. The preferredcutting temperature range is 300° F. to 400° F.

The distal edges of blade portions 266 and 268 may taper to a relativelysharp edge, about 1/32″ (inch) or so. The shape concentrates theapplication of heat to the travelling web of adhered films to enhancepenetration and formation of a precise edge for the pouch flange.

As seen in FIG. 10 , in some applications, such as packaging particulatematter, radial perforator pins 273 may be employed in the space betweenthe blade portions 266 and 268. They may be positioned in apertures ineach pad or block 270 to form microscopic pinholes in the lid film 204during the separation process to allow trapped gases to escape theformed pouches. These perforated holes are small enough to prevent anyparticulate product content to escape from the pouches.

Importantly, in accordance with the disclosure, the shape of the grooves226 and 228 and of the blade portions 266 or 268 can be machined intoany pattern desired. The example of a pouch with an irregular shapedperimeter flange illustrated by FIGS. 4 to 6 of this disclosure isexemplary of the capabilities available through implementation of theprinciples described.

FIG. 11 shows another shape that could be created with a pouchseparation system 380 having a rotary blade drum assembly 350operatively associated with rotary forming drum 320 containing a patternof mold configurations 324. Rotary blade drum assembly 350 may besupported with its rotational axis aligned with the rotational axis offorming drum 350 upon an axially translatable bracket 353 illustrated inFIG. 11 . It is controlled to coact with forming drum 320 in synchronousregistration, as earlier described in connection with the embodiment ofFIGS. 7 to 10 .

Blade drum assembly 350 includes a roller portion 354 upon which arepositioned generally circumferential and generally transverse bladeportions 366 and 368 defining a pattern to form the perimeter edges offlanges of formed pouches. As illustrated, the base forming drum 320 hasgrooves positioned in a complementary pattern to the blade portions 366and 368 of rotary blade drum assembly 350.

Pouch shapes, as in the example of FIG. 11 , derive from a unique shapeof a mold configurations 324 on film support surface 323 of forming drum320. Each mold configuration or cavity 324 is surrounded by generallycircumferential and transverse grooves 326 and 328. These grooves definea tessellated pattern with six (6) sided hexagonal perimeter edges.

Similarly, an illustrated rotary blade drum assembly 350 is providedwith generally circumferential and transverse blade portions 366 and 368in a complementary pattern. Thus, the generally longitudinal andtransverse pattern of grooves surrounding each mold configuration 324and the corresponding pattern of generally longitudinal and generallytransverse blade portions 366 and 368 of the blade drum assembly 350 are“non-linear” in that they are not in all respects parallel to thelongitudinal or transverse extent of the forming drum 324 or travellingweb of adhered films.

Importantly, in this embodiment, the pattern of grooves and bladesencompasses nearly the entire surface 323 of the base forming drum 320and consequently the travelling web of adhered films, thereby minimizingfilm scrap and consumption. The perimeter flange surrounding a completedpouch may be minimized, closely following the perimeter edge of thecompleted pouches. There is thus a film savings may result from usingthe shaped pouch separation system 380 presented in this disclosure. Itis contemplated that any number of intricate patterns could be nested toform a mosaic pattern to, for example, eliminate any ribbons of scrapbetween longitudinal rows of mold configurations.

FIGS. 12 to 14 are illustrative of another unique pouch formingcapability from application of the principles disclosed here.

FIG. 12 shows a product containing pouch 400 of complex configurationproduced from flexible film, such as water-soluble PVA. Here, a formfill and seal machine is employed that is similar to that illustrated inFIG. 3 with a pouch separation system 480 as modified in accordance withthis disclosure. The pouch 400 may include a filled, hollow productcomponent volume surrounded by a flange 411 of adhered base and lidfilms having a perimeter edge 415. The illustrated pouch has a “T-Shirt”shape with a flange 411 having a perimeter edge 415 comprising generallylongitudinal edge portions 412 and generally transverse edge portions414.

As seen in FIG. 13 , a base forming drum, generally 420, includes acylindrical outer film support surface 423 with multiple transverse rowsof mold configurations 424 defining cavities to form product receivingbase pockets of the pouches 400 seen in FIG. 12 . Each moldconfiguration 424 is surrounded by a continuous pattern of generallylongitudinal grooves 426 and generally transverse grooves 428 arrangedin a non-linear manner to create the “T” shirt shape.

Notably, though the pattern of mold configurations 424 extendstransversely in rows that circumferentially surround the outer filmsupport surface 423, the grooves surrounding each mold configuration arespaced from the grooves of other mold configurations. The pattern isillustrative of an option available employing the principles disclosedhere. The pattern of mold configurations 424 is a mosaic of individualspaced apart elements. In this illustration, each row of moldconfigurations is a “mirror image” of adjacent rows.

In accordance with the principles here disclosed, a travelling web ofadhered films with integral filled and sealed pouches 400, within moldconfigurations 424, is carried by the outer film support surface to aseparation station 480, shown in FIG. 14 . It comprises a rotary bladedrum assembly 450, best seen in FIG. 13 , disposed in operativeassociation with base forming drum 420. It is mounted for adjustablemovement relative to base forming drum 420 and powered to rotate incontrolled synchronous registry with the grooves 426 and 428 of baseforming drum 420, as previously described in connection with theembodiment of FIGS. 4 to 10 . It should be noted that the rotary bladedrum 350 and base forming drum 320 of the embodiment of FIG. 11 are, ofcourse, similarly configured and arranged in a rotary form, fill andseal pouch forming machine.

In FIG. 14 , there is illustrated rotary blade drum assembly 450 of thepouch separation system 480 of FIG. 13 . It is mounted in a rotary form,fill and seal pouch forming machine in operative association with outerfilm support surface 423 for controlled functional coaction, all asherein previously described.

Assembly 450 includes a roller portion having an outer cylindrical drumcontact surface 455 defined by radially outer surfaces of resilientinsulating pads or guides 470, as previously described in connectionwith the embodiment of FIGS. 9 and 10 . The roller portion has an axiallength generally coextensive with the transverse width of base formingdrum 420. When the base forming drum 220 and rotary blade drum assembly450 are in operative relation to each other, outer cylindrical drumcontact surface 455 is in rolling contact with the travelling web ofadhered films carried upon outer film support surface 423 of baseforming drum 420. The rotary blade drum assembly 450 is urged towardrotating base forming drum 420 to maintain this operating relationship.The effective diameter of the outer cylindrical drum contact surface455, defined by the outer surfaces of silicone pads 470, is such thatthe outer film support surface 423 and the cylindrical drum contactsurface 455 travel at the same linear velocity.

As seen in FIG. 14 , rotary blade drum assembly 450 includes generallylongitudinal or circumferential blade portions 466 and generallytransverse blade portions 468 that extend radially outward of outercylindrical drum contact surface 455. The blade portions 466 and 468 maybe machined or otherwise formed or affixed to rotary blade drum assembly450. They are configured to interengage or mesh with the grooves 426 and428 of the base forming drum 420, as in the earlier embodiments.

Blades 466 and 468 include distal end portions that extend radiallyoutward of outer cylindrical drum contact surface 455 and are configuredto mesh with the generally circumferential grooves 426 and generallytransverse grooves 428 of the base forming drum 420. They, consequently,define the perimeter edge 415 of pouch 400. Thus, the blade portions 466and 468 form a separation perimeter sized and arranged to engage thetravelling web of films on other film support surface 423 and separateindividual pouches 400 within each perimeter. The distal edges of theblades 466 and 468 extend beyond the silicone insulation pads 270 andenter the grooves machined into the drum 420 without touching the drumor surfaces defining grooves 426 or 428.

As illustrated, the rotary blade drum assembly 450 has four completepatterns of intersecting blade portions 466 and 468 circumferentially ofdrum 450 and has a diameter substantially smaller than the diameter ofcylindrical outer film support surface 423 of base forming drum 420.With blades 466 and 468 in register with grooves 426 and 428, the outerfilm support surface 423 and outer cylindrical drum contact surface 455travel at the same linear velocity to maintain synchronous registry.

As in the earlier embodiments, the rotary blade drum assembly 450includes inserted wound cartridge resistive heating elements 451,represented in FIG. 13 , that heat blade portions 466 and 468 to atemperature sufficient to melt the web of films on contact, usuallybetween 300° and 400° F.

To prevent the heated rotary blade drum or roller 450 from damaging thepouches during the separation process, each intermediate area within theperimeter defined by intersecting generally circumferential andtransverse blade portions 466 and 468, is provided with insulatingmaterial in the form of the silicone pads or blocks 470. These padsprotect the pouches within the area defined by the intersecting bladesfrom undesired contact with metal elements of rotary blade drum assembly450. During separation from the travelling web of adhered films, thesilicone pads 470 contact each pouch being separated and urge thepouches toward the associated mold configuration 424 in the base formingdrum 420 to prevent the tensioned film of the pouch from prematurelyrecovering and changing the shape of the pouch or causing pouch movementthat would cause contact with the blade portions 466 and 468.

With reference to the above description and disclosure, it must beunderstood that the illustrated base forming drums 220, 320 or 420 aresubstituted for the base forming drum 120 of the machine of FIG. 3 .During pouch forming, these drums support a base film that, in the usualmanner, is drawn into the plurality of mold configurations 224, 324 or424 under applied heat and vacuum. These base pockets are then filledwith product and covered with a lidding film again in the usual mannerof forming such flexible pouches. One or both of the base film and lidfilm are wetted or coated with adhesive to ensure adherence betweencontacting surfaces to form sealed product containing chambers orpouches. While under continued vacuum within the mold configurationcavities, the moving web of adhered films and interspersed pouches isdelivered to a separation mechanism in accordance with the presentdisclosure. The heated rotary blade drum assembly 250, 350 or 450, withspecially shaped longitudinal blade portions 266, 366 or 466 andtransverse blade portions 268, 368 or 468 coact with the associatedgenerally circumferential and transverse grooves of the base formingdrum 220, 320 or 420 and melt the film on contact to separate entirepouches from the film web. The pouches are retained in the base drummold cavities until the vacuum is released at which time the pouches arereleased and delivered to a conveyor for further processing orpackaging. Each resultant pouch emerges with a perimeter flange definedby the blade portions 266 and 268, 366 and 368, or 466 and 468 of rotaryblade drums 250, 350 or 450, as already explained.

It should also be understood that equipment illustrated in FIG. 3 isalso intended to function as described herein. In this regard, pouchseparation station 180 includes blade drum assembly 150 provided withlongitudinal blade portions and transverse blade portions aligned tocoact in synchronous registration with the intersecting groovessurrounding the mold configurations in the outer film support surface123 of base forming drum 120. The blade drum assembly 150 may, in allother respects, structurally and functionally duplicate the blade drumassembly 250 of separation station 280, described herein in detail.

In the example shown in FIGS. 4 to 9 , transverse groove portions 228and transverse blade portions 268 are arranged in a linear pattern.However, these groove and blade portions could also be irregularlyshaped to provide a unique separation pattern transverse of the baseforming drum 220 and travelling web of films. In that instance, aspecially shaped edge 214 would be created upon the pouch flange 211. Itshould be understood that the embodiments illustrated herein are onlyillustrative and numerous other pouch separation system componentconfigurations may be derived or implemented in accordance with theprinciples of this disclosure.

Notably, the rotary blade drums 250, 350 or 450 operate at elevatedtemperatures, and the temperature of base forming drums 220, 320 or 420may also be minimally elevated. Therefore, in sizing and forming theblade portions to maintain registry with the pattern of grooves on theassociated base forming drums, it is necessary to accommodate thermalexpansion or size change of the machine components. One successfulapproach has been to make calculations based on a fixed end of the shaftupon which the rotary drum rotates relative to the position of therotating base forming drum to determine applicable expansion factors.

It will be appreciated that the foregoing description provides examplesof the disclosed system and technique. However, it is contemplated thatother implementations of the disclosure may differ in detail from theforegoing examples. All references to the disclosure or examples thereofare intended to reference the particular example being discussed at thatpoint and are not intended to imply any limitation as to the scope ofthe disclosure more generally. All language of distinction anddisparagement with respect to certain features is intended to indicate alack of preference for those features, but not to exclude such from thescope of the disclosure entirely unless otherwise indicated.

Recitation of ranges of values herein are merely intended to serve as ashorthand method of referring individually to each separate valuefalling within the range, unless otherwise indicated herein, and eachseparate value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context.

Accordingly, this disclosure includes all modifications and equivalentsof the subject matter recited in the claims appended hereto as permittedby applicable law. Moreover, any combination of the above-describedelements in all possible variations thereof is encompassed by thedisclosure unless otherwise indicated herein or otherwise clearlycontradicted by context.

The invention claimed is:
 1. Apparatus for separating product containingpouches from a travelling web of adhered films comprising: a filmsupport surface carrying the adhered films and provided with pouchforming mold configurations having a perimeter edge at said film supportsurface defining the cavity of each mold configuration; said filmsupport surface including groove portions between said moldconfigurations surrounding each said mold configuration; a rotary bladedrum assembly in operative relation with said film support surfacehaving blade configurations with blade portions arranged to form theentire perimeter edge of the flange of the pouch; said blade portionsarranged to interengage with said groove portions of said film supportsurface, with distal ends arranged to enter said groove portions of saidfilm support surface; rotation of said rotary blade drum causing saiddistal ends of said blade portions to enter said groove portions throughsaid travelling web of adhered films and form said perimeter edge of theflange of the pouch and separate said pouches from the travelling web ofadhered films.
 2. Apparatus for separating product containing pouchesfrom a travelling web of adhered films, as claimed in claim 1, wherein arotating forming drum includes said film support surface.
 3. Apparatusfor separating product containing pouches from a travelling web ofadhered films, as claimed in claim 2, wherein said film support surfaceincludes intersecting generally longitudinal groove portions andgenerally transverse groove portions between said mold configurations,and said rotary blade drum assembly includes intersecting generallylongitudinal blade portions and generally transverse blade portionsconfigured to interengage with said generally longitudinal and generallytransverse groove portions.
 4. Apparatus for separating productcontaining pouches from a travelling web of adhered films, as claimed inclaim 3, wherein said forming drum includes a plurality of said moldconfigurations arranged in circumferential rows spaced transversely ofsaid film support surface.
 5. Apparatus for separating productcontaining pouches from a travelling web of adhered films, as claimed inclaim 4, wherein at least one of said generally longitudinal bladeportions or generally transverse blade portions for synchronousregistration with each of said groove portions is non-linear relative tothe longitudinal or transverse extent of said forming drum or travellingweb of adhered films.
 6. Apparatus for separating product containingpouches from a travelling web of adhered films, as claimed in claim 4,wherein said rotary blade drum assembly includes heating elements toheat said blade portions to a temperature in the range of 140° to 400°F.
 7. Apparatus for separating product containing pouches from atravelling web of adhered films, as claimed in claim 4, wherein saidrotary blade drum assembly includes insulating pads disposed within eachblade configuration said insulating pads arranged to define a contactsurface disposed to contact pouches being separated from said travellingweb of adhered films.
 8. Apparatus for separating product containingpouches from a travelling web of adhered films, as claimed in claim 7,wherein said forming drum and rotary blade drum assembly are arrangedsuch that said film support surface of said forming drum and saidgenerally cylindrical forming drum contact surface of said rotary bladedrum contact opposite sides of said travelling web of adhered films andsaid surfaces travel at the same linear velocity.
 9. A rotary blade drumand forming drum assembly for separating product containing pouches froma travelling web of adhered films comprising: a film support surface onsaid forming drum provided with a plurality of pouch forming moldconfigurations having a perimeter edge of said film support surfacedefining the cavity of each mold configuration and groove portions,including intersecting generally longitudinal groove portions andgenerally transverse groove portions between said mold configurations; arotary blade drum assembly having a plurality of blade configurationseach with blade portions including intersecting generally longitudinalblade portions and generally transverse blade portions arranged to formthe entire perimeter edge of the flange of a pouch; said blade portionsarranged to interengage with the groove portions in the film supportsurface in the forming drum, with distal ends arranged to enter saidgroove portions of said film support surface, rotation of said formingdrum and said rotary blade drum causing said distal ends of said bladeportions to enter said groove portions through the travelling web ofadhered films and form the perimeter edge of the flange of the pouch andseparate pouches from the travelling web of adhered films.
 10. A rotaryblade and forming drum assembly, as claimed in claim 9, wherein saidrotary blade drum assembly includes insulating pads disposed within eachblade configuration, said insulating pads include a contact surface tocontact pouches during separation from said travelling web of adheredfilms, and wherein said rotary blade drum includes heating elements toheat said blade portions.
 11. A rotary blade and forming drum assemblyfor separating product containing pouches from a travelling web ofadhered films, as claimed in claim 9, wherein said longitudinal grooveportions and longitudinal blade portions are non-linear relative to thelongitudinal extent of the forming drum or travelling web of adheredfilms.
 12. A rotary blade and forming drum assembly for separatingproduct containing pouches from a travelling web of adhered films, asclaimed in claim 9, wherein said multiple blade configurations arenested in the transverse direction with a longitudinal blade portion ofeach blade configuration comprising a longitudinal blade portion of anadjacent blade configuration.